Clutch jobs - I5 transes

[QSHIPQ@aol.com]

In a message dated 97-01-04 19:35:08 EST, you write:

<< Hmmm. To me it would be like trying to reach a left ear with a right
 foot, even on a quattro. Your's is not a quattro, right? Whenever I did
 it on FWD or RWD, I never needed more than 80 cm of clearance between
 the garage floor and the car bottom. You can remove and install a FWD
 tranny with the help of an assistant quite easily. Never tried it on a
 quattro, though. Should be a nightmare to do it without a lift. I did it
 on an AWD car only once (a Mitsu (Colt) Vista). It was
 one_horrible_experience! Then again, I had no lift and it was a japanese
 made car, almost as mechanic-hostile, as anything from Big Three. On top
 of that the engine was transverse mounted.
 
 Igor >>
....  Done more of these on the floor than my aging back cares to admit, and
I have 3 more waiting for me...  Yes, the fwd can be dropped with the motor,
but not necessary, in fact, hardly necessary, you are adding all sorts of
time to a pretty straight forward job....  I had posted the procedure a while
back, just looked thru my volumes here in pc land, can't find, but bet it's
in the archives....   Highlites:

*  no don't drop the  motor, that adds at least another day to the procedure,
no vital fluid drain the proper way
*  make sure you put a crossbrace on the front motor mount, otherwise the
motor will rock forward on the side mounts, and the trans will never go back
in
*  The wheels and driveshafts can be left on the car, just disconnect them at
the trans
*  Remove subframe assbly, can be removed and installed by single person (all
mine were by yours truely)
*  remove starter
*  remove trans wings where they go to subframe, you cheese on this, and you
will get stuck partway down....
*  Pop off the shift linkage
*  Remove exhaust system cat back only....  You prolly need to just remove
the donuts and move the system back some to get the drop room, but by
then....
*  slide clutch slave out of top of trans, no need to remove the line unless
the slave turns out to be a schtuck one, then remove the line at the MC side
and pull trans with slave in it...
*  Find ALL the bolts, 19, 17, 15, 13mm engine to trans...
*  I put the car on jack stands (not on subframe please) then floor jack the
trans back and down....
*  flywheel cut, ck to make sure they put the pins back in (hello) install
new clutch assbly, do not cut a bowl flywheel (pre 89.5 quattros), it is a
tapered cut, that is better left just cleaned with sandpaper
*  install new seal at trans spline shaft
*  inspect your pilot bearing, it should have a rubber seal in it, if not,
replace
*  Good time to add that Redline to the trans, the 17mm hex is available at
sears for 8.99
*  lightly lube spline, do it, this is a very tight fitting trans to block
thing
*  The last 2 inches trans to block has been a bolt draw for me every time...
*  My Bentley favourite, "install reverse of removal" one sentence=4 hours
*  New ball joint bolts please
*  There are seals on the driveshaft flanges, you won't be able to salvage
what's you got easily...
*  Most of the time all the jockying pops the shifter out of it's bulb in the
car, just pound it back into the pocket with your palm...  make sure the
spring is underneath first...

First time, count on 2 days, after that, you can help friends do it in about
8 man hours total...

Only difference between quattro and fwd is the removal/install of the rear
driveshaft, about 15 more minutes....  The rear driveshaft (quattros) can be
tied up to the side, you don't need to take it out....  The driveshaft
carrier needs to be removed tho....

I did a total breakdown of this procedure in my former post, I'll see if I
can find it, but happy to share all the tricks to that one...  It is not a
huge job, and is definitely possible on the back with a floor jack, that is
THE only way I've done them....  Another body helps too, cuz it is just
LABOR.....  

HTH. If you need more detail, ck the archives...  No luck, post me again, I'm
sure I have them somewhere....

Scott